Conveyor flange adapter

ABSTRACT

A one-piece conveyor flange adapter designed for hollow bore, direct drive configurations. A dual flange casting has two opposite flanges machined and bored to attach between a mounting plate on an electric motor speed reducer housing and a similar mounting plate on a conveyor drive frame. The adapter has a large central axial opening between the two parallel plates, through which a rotating drive shaft extends. The adapter is bolted in place between the speed reducer housing and the conveyor drive frame. The flange adapter has a base mounted on the speed reducer. The outer cruciform flange mounts directly on the conveyor frame with two or four bolt connections. The conveyor drive shaft fits through the opening and connects to gears inside the reducer. Alternatively, the reducer has an output shaft that extends through the opening and directly connects to the conveyor drive.

BACKGROUND OF THE INVENTION

Present methods of connecting speed reducers to conveyor systems arecost and labor intensive. The cumbersome existing methods for mountingspeed reducers on conveyors require extensive amounts of time and laborfor installation and maintenance. A traditional drive system mountingmethod can take experienced technicians hours to install. The costs ofinstallation and maintenance add up quickly when considering the milesof conveyor lines in any commercial warehouse. Furthermore, time andmanpower is lost on paperwork, phone calls and receiving time associatedwith sourcing multiple components.

These existing systems generally include a reducer, two mountedbearings, a motor, two sprockets, a chain, a chain guard and mountingbrackets. Often, systems are incompatible with certain parts orcomponents because the systems utilize various bolt mounted bearings.Common problems associated with existing conveyor systems are related toshock loads. Shock loads can cause chain stretch, sprocket changeoversand other damaging effects.

Needs exist for simpler conveyor flange adaptors with fewer componentsthat are easier and quicker to install.

SUMMARY OF THE INVENTION

The present invention is an innovative one-piece conveyor flangedesigned for hollow bore, direct drive configurations. A dual flangecasting has two opposite flanges machined and drilled to attach betweena mounting plate on an electric motor speed reducer housing and asimilar mounting plate on a conveyor drive frame. The adapter has alarge central axial opening between the two parallel plates, throughwhich a rotating drive shaft extends. The adapter is bolted in placebetween the speed reducer housing and the conveyor drive frame. Theflange adapter has a base mounted on the speed reducer. The outercruciform flange, with six drilled holes, slots or enclosed scallopedslots, mounts directly on the conveyor frame with two or four boltconnections. Rubber grommets may pass through the enclosed scallopedslots. The conveyor drive shaft fits through the opening and connects togears inside the reducer. Alternatively, the reducer has an output shaftthat extends through the opening and directly connects to the conveyordrive.

The conveyor flange drive speed reducer adapter of the present inventionprovides a direct conveyor drive and eliminates bearing flanges, drivesprockets, driven sprockets, roller chains, chain guards and reducermounting brackets. The present invention also reduces the space and costassociated with installing and maintaining such devices.

The conveyor flange of the present invention decreases maintenanceassembly and disassembly time by approximately 75% due to the reductionin components and the decrease in complexity. The present invention alsoreduces the overall cost of a power transmission drive by about 40%. Thereduction in components also reduces the amount of space required in aplant for the systems. The present invention is compatible with existingsystems and may be used with both two and four bolt mountings.

These and further and other objects and features of the invention areapparent in the disclosure, which includes the above and ongoing writtenspecification, with the claims and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a blank conveyor flange adapter.

FIG. 2 is a front view of a conveyor flange adapter with drilled holes.

FIG. 3 is a cross sectional side view of the conveyor flange adaptertaken along the line A-A in FIG. 2.

FIG. 4 is a perspective view of the conveyor flange adapter mounted andattached to a speed reducer housing, which is directly coupled to adrive motor.

FIG. 5 is a front view of a conveyor flange adapter with drilled holes.

FIG. 6 is a cross sectional side view of the conveyor flange adaptertaken along the line A-A in FIG. 5.

FIG. 7 is a perspective view of the conveyor flange adapter mounted andattached to a speed reducer housing, which is directly coupled to adrive motor.

FIG. 8 is a perspective view of the conveyor flange adapter withenclosed, scalloped slots.

FIG. 9 is a side view of the conveyor flange adapter with enclosed,scalloped slots.

FIG. 10 is a rear view of the conveyor flange adapter with enclosed,scalloped slots.

FIG. 11 is a front view of the conveyor flange adapter with enclosed,scalloped slots.

FIG. 12 is a cross sectional side view of the conveyor flange adaptertaken along the line A-A in FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is an innovative one-piece conveyor flangedesigned for hollow bore, direct drive configurations.

FIG. 1 is a front view of a blank conveyor flange adapter 9. The blankconveyor flange adapter 9 is stored in inventory. The conveyor flangeadapter 9 has two opposite parallel flanges, a front flange 13 and aback flange 15. The back flange 15 is machined and bored to attach to amounting plate 17 on an electric motor speed reducer housing 19, asshown in FIG. 4. FIG. 2 is a front view of a conveyor flange adapter 11.The front flange 13 is machined and bored to attach to a similarmounting plate on a conveyor drive frame for driving the conveyor with ashaft directly coupled to the speed reducer. The conveyor flange adapter11 has a large, central, axial opening 21 between the two parallelflanges 13, 15. A rotating drive shaft extends through the opening 21.

The conveyor flange adapter 11 is bolted in place between the speedreducer housing 19 and the conveyor drive frame. Four bolts 23 arepassed through holes 25 in the flange 15 to connect the flange 15 to thespeed reducer housing 19. Bolts 23, shown in FIG. 4, attach the backflange 15 to threaded bores in the speed reducer mounting plate 17.Similar bolts 23 are passed through one or more drilled holes 27 on thefront flange 13 to connect the front flange 13 to the conveyor directdrive frame. Preferably, the conveyor flange adapter 11 has six drilledholes 27 so that two or four threaded bores on the conveyor frame may beused. The drilled holes 27 are sized to correspond to particular sizedmounting bolts used in existing connection systems. For example, boltsmay be preferably, but not limited to, ⅜″ or 7/16″.

The conveyor drive shaft fits through the opening 21 and connects to anoutput gear inside the speed reducer. Alternatively, the speed reducerhas an output shaft that extends through the opening 21 and directlyconnects to the conveyor drive.

FIG. 3 is a cross sectional view of the conveyor flange adapter 11 takenalong line A-A in FIG. 2. The diameter of the opening 21 varies throughthe conveyor flange adapter 11 to accommodate the drive shaft andbearings in cylindrical sectors 37, 39 and 41. Between the front flange13 and the back flange 15 is a neck 29. The neck 29 may be taperedoutward from the front flange 13 out to the back flange 15. Protrudingfrom the back flange 15 is a connector 31 that interacts with theconnection system on the speed reducer housing 19. The connector 31 hasa collar 33 with a groove 35 to hold an o-ring seal for sealing theinterior gear case in the speed reducer housing 19.

FIG. 4 is a perspective view of the conveyor flange adapter 11 attachedto the speed reducer housing 19.

FIG. 5 is a front view of a conveyor flange adapter 43 with slots 45.The conveyor flange adapter 43 has two opposite parallel flanges, afront flange 13 and a back flange 15. The back flange 15 is machined andbored to attach to a mounting plate 17 on an electric motor speedreducer housing 19, as shown in FIG. 7. The front flange 13 is machinedand bored to attach to a similar mounting plate on a conveyor driveframe for driving the conveyor with a shaft directly coupled to thespeed reducer. The conveyor flange adapter 43 has a large, central,axial opening 21 between the two parallel flanges 13, 15. A rotatingdrive shaft extends through the opening 21.

The conveyor flange adapter 43 is bolted in place between the speedreducer housing 19 and the conveyor drive frame. Four bolts 23 arepassed through holes 25 in the flange 15 to connect the flange 15 to thespeed reducer housing 19. Bolts 23, shown in FIG. 7, attach the backflange 15 to threaded bores in the speed reducer mounting plate 17.Similar bolts 23 are passed through one or more slots 45 on the frontflange 13 to connect the front flange 13 to the conveyor direct driveframe. Preferably, the conveyor flange adapter 43 has six slots 45 sothat two or four threaded bores on the conveyor frame may be used. Theslots 45 are sized to correspond to particular sized mounting bolts usedin existing connection systems. For example, bolts may be preferably,but not limited to, ⅜″ or 7/16″.

The conveyor drive shaft fits through the opening 21 and connects to anoutput gear inside the speed reducer. Alternatively, the speed reducerhas an output shaft that extends through the opening 21 and directlyconnects to the conveyor drive.

FIG. 6 is a cross sectional view of the conveyor flange adapter 43 takenalong line A-A in FIG. 5. The diameter of the opening 21 varies throughthe conveyor flange adapter 43 to accommodate the drive shaft andbearings in cylindrical sectors 37, 39 and 41. Between the front flange13 and the back flange 15 is a neck 29. The neck 29 may be taperedoutward from the front flange 13 out to the back flange 15. Protrudingfrom the back flange 15 is a connector 31 that interacts with theconnection system on the speed reducer housing 19. The connector 31 hasa collar 33 with a groove 35 to hold an o-ring seal for sealing theinterior gear case in the speed reducer housing 19.

FIG. 7 is a perspective view of the conveyor flange adapter 43 attachedto the speed reducer housing 19.

FIG. 8 is a front view of a conveyor flange adapter 51 with enclosed,scalloped slots 53. The conveyor flange adapter 51 has two oppositeparallel flanges, a front flange 13 and a back flange 15. The backflange 15 is machined and bored to attach to an electric motor speedreducer housing 19. The front flange 13 is machined and bored to attachto a similar mounting plate on a conveyor drive frame for driving theconveyor with a shaft directly coupled to the speed reducer. Theconveyor flange adapter 51 has a large, central, axial opening 21between the two parallel flanges 13, 15. A rotating drive shaft extendsthrough the opening 21.

The conveyor flange adapter 51 is bolted in place between the speedreducer housing 19 and the conveyor drive frame. Four bolts 23 arepassed through the flange 15 to connect the flange 15 to the speedreducer housing 19. Other bolts 55 are passed through one or moreenclosed, scalloped slots 53 on the front flange 13 to connect the frontflange 13 to the conveyor direct drive frame. Preferably, the conveyorflange adapter 51 has six slots 53 so that two or four threaded bores onthe conveyor frame may be used. The slots 53 are sized to correspond toparticular sized mounting bolts used in existing connection systems.Rubber grommets 57 or other similar devices may surround the bolts 55.Scallops 59 capture the bolts 55 and corresponding grommets 57 in theappropriate location.

The conveyor drive shaft fits through the opening 21 and connects to anoutput gear inside the speed reducer. Alternatively, the speed reducerhas an output shaft that extends through the opening 21 and directlyconnects to the conveyor drive. The diameter of the opening 21 variesthrough the conveyor flange adapter 51 to accommodate the drive shaftand bearings. Between the front flange 13 and the back flange 15 is aneck 29. The neck 29 may be tapered outward from the front flange 13 outto the back flange 15.

FIG. 9 is a side view of the conveyor flange adapter 51 with enclosed,scalloped slots 53. FIGS. 10-12 are various views of the conveyor flangeadapter 51 with enclosed, scalloped slots 53.

The conveyor flange drive speed reducer adapter of the present inventionprovides a direct conveyor drive and eliminates bearing flanges, drivesprockets, driven sprockets, roller drive chains, chain guards andreducer mounting brackets. The present invention also reduces the spaceand cost associated with installing and maintaining such devices.

The conveyor flange of the present invention decreases maintenanceassembly and disassembly time by approximately 75% due to the reductionin components and the decrease in complexity. The present invention alsoreduces the overall cost of a power transmission drive by about 40%. Thereduction in components also reduces the amount of space required in aplant for the systems. The present invention is compatible with existingsystems and may be used with both two and four bolt mountings.

While the invention has been described with reference to specificembodiments, modifications and variations of the invention may beconstructed without departing from the scope of the invention, which isdefined in the following claims.

1. A single piece conveyor flange adapter comprising: first and secondflanges connected together by a neck, a central axial opening throughthe neck and between the first and second flanges, one or more holes inthe first flange for passing bolts through the first flange and into aconveyor drive frame, and one or more holes in the second flange forpassing bolts through the second flange and into a speed reducerhousing.
 2. The apparatus of claim 1, wherein the conveyor flangeadapter is used on hollow bore, direct drive configurations.
 3. Theapparatus of claim 1, wherein either two or four bolts are used tosecure the conveyor flange adapter on the speed reducer housing and onthe conveyor drive frame.
 4. The apparatus of claim 1, wherein the firstflange has six drilled holes.
 5. The apparatus of claim 1, wherein theone or more holes on the first flange are slots.
 6. The apparatus ofclaim 1, wherein the one or more holes on the first flange are enclosed,scalloped slots.
 7. The apparatus of claim 1, further comprising rubbergrommets surrounding the bolts passing through the first flange.
 8. Theapparatus of claim 1, wherein the conveyor flange adapter is stored as ablank in inventory and the one or more holes in the first flange and theone or more holes in the second flange are sized and created forparticular uses when the conveyor flange adapter is removed frominventory.
 9. The apparatus of claim 1, wherein a conveyor drive shaftextends through the central axial opening between the first and secondflanges.
 10. The apparatus of claim 9, wherein the conveyor drive shaftconnects to gears inside a speed reducer.
 11. The apparatus of claim 1,further comprising an output shaft extending through the central axialopening between the first and second flanges and directly connecting toa conveyor drive.
 12. The apparatus of claim 1, wherein the diameter ofthe central axial opening varies along the length of the central axialopening.
 13. The apparatus of claim 1, further comprising a connectionsystem on the second flange for connecting the second flange to thespeed reducer housing.
 14. A method of connecting a speed reducer to aconveyor drive comprising: providing a conveyor flange adaptercomprising: first and second flanges connected together by a neck, acentral axial opening between the first and second flanges, one or moreholes in the first flange, and one or more holes in the second flange,passing a conveyor drive shaft through the central axial opening betweenthe first and second flanges, securing bolts through the one or moreholes in the first flange and a conveyor drive frame, and securing boltsthrough the one or more holes in the second flange and a speed reducerhousing.
 15. The method of claim 14, wherein the conveyor flange adapteris used on hollow bore, direct drive configurations.
 16. The method ofclaim 14, wherein either two or four bolts are used to secure theconveyor flange adapter on the speed reducer housing and on the conveyordrive frame.
 17. The method of claim 14, wherein the one or more holeson the first flange are slots.
 18. The method of claim 14, wherein theone or more holes on the first flange are enclosed, scalloped slots. 19.The method of claim 14, wherein rubber grommets surround the boltspassing through the first flange.
 20. The method of claim 14, furthercomprising storing the conveyor flange adapter as a blank in inventoryand providing the one or more holes in the first flange and the one ormore holes in the second flange for particular uses when the conveyorflange adapter is removed from inventory.
 21. The method of claim 14,wherein the conveyor drive shaft connects to gears inside a speedreducer.
 22. The method of claim 14, wherein the conveyor drive shaftconnects directly to a conveyor drive.
 23. The method of claim 14,wherein the diameter of the central axial opening varies along thelength of the central axial opening.
 24. The method of claim 14, whereinthe conveyor flange adapter further comprises a connection system on thesecond flange for connecting the second flange to the speed reducerhousing.